Study on necking defects, microstructure and mechanical properties of TC4 alloy by cross wedge rolling

Li, Peiai; Wang, Baoyu; Yang, Chen; Zhang, Huibo; Li, Wei; Zhou, Jing

doi:10.1007/s12289-022-01718-z

Cited by 3 publications

(2 citation statements)

References 28 publications

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“…Peng et al [ 87 ] analyzed 46 cases of CWR to determine wear characteristics of the wedge tools. Li et al [ 88 , 89 ] investigated the CWR of a vehicle arm preform to determine the optimum temperature of the billet. Feng et al [ 90 , 91 ] investigated the production of a hollow shaft by CWR with a mandrel.…”

Section: Cwr Formation Of Parts Made Of Non-ferrous Materialsmentioning

confidence: 99%

The Application of Finite Element Method for Analysis of Cross-Wedge Rolling Processes—A Review

Pater

2023

Materials

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The aim of this article is to review the application of the finite element method (FEM) to cross-wedge rolling (CWR) modeling. CWR is a manufacturing process which is used to produce stepped axles and shafts as well as forged parts for further processing on forging presses. Although the concept of CWR was developed 140 years ago, it was not used in industry until after World War 2. This was due to the limitations connected with wedge tool design and the high costs of their construction. As a result, until the end of the twentieth century, CWR tools were constructed by rolling mill manufacturers as they employed engineers with the most considerable experience in CWR process design. The situation has only changed recently when FEM became widely used in CWR analysis. A vast number of theoretical studies have been carried out in recent years, and their findings are described in this overview article. This paper describes nine research areas in which FEM is effectively applied, namely: the states of stress and strain; force parameters; failure modes in CWR; material fracture; microstructure modeling; the formation of concavities on the workpiece ends; CWR formation of hollow parts; CWR formation of parts made of non-ferrous materials; and new CWR methods. Finally, to show the potential of FEM on CWR modeling, a CWR process for manufacturing a stepped shaft used in car gearboxes is simulated numerically. This numerical simulation example shows that FEM can be used to model very complex cases of CWR, which should lead to a growing interest in this advanced manufacturing technique in the future.

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Section: Cwr Formation Of Parts Made Of Non-ferrous Materialsmentioning

confidence: 99%

The Application of Finite Element Method for Analysis of Cross-Wedge Rolling Processes—A Review

Pater

2023

Materials

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“…Zheng the feasibility of CWR forming of light metals including aluminum alloys (6101A; 2681A), titanium alloys (Ti6Al4V), and magnesium alloys (AZ31; AZ61; Mg4AlZnMn), and pointed out that magnesium alloys can be formed smoothly only at lower relative diameter reduction ratio δ owing to its poor plasticity [20]. Li et al [21] found that TC4 titanium alloy was prone to necking when rolled at 950°C due to the material softening effect and axial tensile deformation, and proposed that multi-pass CWR forming can be used to avoid necking defects. Li et al [22,23] also successively investigated the CWR forming of TC6 titanium alloy and GH4169 superalloy via simulations and experiments.…”

Section: Introductionmentioning

confidence: 99%

Numerical and experimental analysis of defects control in cross wedge rolling for titanium alloy workpieces

SHI,

Cheng,

Liu

et al. 2024

Preprint

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Through the optimization of tool parameters and the wedge shape, titanium alloy workpieces with excellent surface and internal qualities were formed by flat cross wedge rolling (CWR) adopting tools without surface grooves. Firstly, the thermomechanical coupled model of CWR for TC11 (Ti-6.5Al-3.5Mo-1.5Zr-0.3Si) titanium alloy was established in the finite element (FE) software DEFORM-3D, and the effects of forming angle α, stretching angle β and section reduction Ψ were studied. The results showed that in the conventional empirical range of tool parameters, the defect-free workpiece is hard to be rolled by the typical tool structure. To optimize the forming quality of rolled workpieces, a modified tool structure was proposed by introducing an inclined plane with a width of λ (2–5 mm) on the top of the wedge shape and revising the side wedge plane α to a combination of two inclined planes α1 and α2 (α ≥ α1 > α2). Simulations and experiments demonstrated that the modified tools without surface grooves can achieve TC11 alloy workpieces with smooth surface. When the distance between the top and bottom tools is too large, the rolled workpiece axis is prone to being bent, and the gap from the top tool to the billet should be controlled in the range of 0-0.2 mm to ensure its straightness. Finally, the necking-free TC11 alloy rolled workpieces (Ψ = 67.9% and Ψ = 82.3%) with smooth surface and excellent internal quality were manufactured by IM500 flat CWR mill at 900°C, 500 mm/s.

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Internal defects control mechanism and process optimization of TC11 titanium alloy by cross wedge rolling

Shi¹,

Cheng²,

Liu³

et al. 2023

Journal of Materials Processing Technology

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Study on necking defects, microstructure and mechanical properties of TC4 alloy by cross wedge rolling

Cited by 3 publications

References 28 publications

The Application of Finite Element Method for Analysis of Cross-Wedge Rolling Processes—A Review

The Application of Finite Element Method for Analysis of Cross-Wedge Rolling Processes—A Review

Numerical and experimental analysis of defects control in cross wedge rolling for titanium alloy workpieces

Internal defects control mechanism and process optimization of TC11 titanium alloy by cross wedge rolling

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